PI85 INSTRUCTIONS BOOK HYDRAULIC PRESS FOR LOCKS

Transcription

1 HYDRAULIC PRESS FOR LOCKS PI85 INSTRUCTIONS BOOK PRADA NARGESA, S.L Ctra. de Garrigàs a Sant Miquel s/n PALAU DE STA. EULALIA (GIRONA) SPAIN Tel Fax nargesa@nargesa.com

2 Thank you for choosing our machines

3 INDEX 1. CHARACTERISTICS OF THE MACHINE General dimensions Description of the machine Machine identification General features TRANSPORT AND STORAGE Transport Storage conditions MAINTENANCE General maintenance Greasing of punches INSTALLMENT AND STARTING UP Machine location Dimensions and working place Admisible outer conditions Connection to power supply Assembling the mandrel back support Responsibilities OPERATIONS MANUAL Mechanism perforation Simultaneous perforation of the bulb shape cavity and the handle Perforation by parts Punch extraction Perforation with just one punch Perforation of bulb shape cavity and handle in just one side Punching with 2mm thick tubes WARNINGS TOOLINGS TECHNICAL ANNEX INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 2

4 1. CHARACTERISTICS OF THE MACHINE Make Type Model Nargesa Troqueladora de cerraduras PI General dimensions 1.2. Description of the machine Hydraulic press PI85, are specifically designed for the tube perforation of the different bulb shape locks cavities existing in the market, which are more than 80%. It allows the perforation of the mechanism set, the bulb shape cavity and the handle at the same time. Moreover, it is possible to make the independent bulb shape cavity and the handle perforation which permits to vary the distance between them. PI85 have a milimetrical system incorporated in order to allow the regulation of the mechanism box, the bulb shape cavity and the handle; so it can make distances from 18 up to 37 mm. PI85 is according to the European directives and regulations for machine manufacturing. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 3

5 1.3. Machine identification Frontal protector Frontal protector Madrill Plate fixing Stop emergency Top Top dipstick Back stand Pedal Frontal protector Upper top Lower cut plate Front top INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 4

6 1.4. General features Engine Power 3-phased tension Pump Maximum pressure Pipe thickness Lock entrance 0,75 KW / 1 CV a 1410 r.p.m. 3,3 A a 230 V / 1,9 A a 400 V 230 / 400 V 1,5 l 200 bars 1,5 y 2mm Adjustable from 18 to 37mm Total time for the operation 58 s. Dimensions Weight 1500x570x1470mm 200 Kg TUBES THAT CAN BE WORKED WITH 35x35 40x40 40x50 40x60 40x70 40x80 50x50 50x60 50x70 50x80 INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 5

7 2. TRANSPORT AND STORAGE 2.1. Transport The machine is equiped with a stand or lower base thought for the transport of the machine by using a lifting truc placing it in the midle of the stand keeping in mind not to lift it more than what s necessary to avoid a possible overturning. In case it has to be lifted it has a clamping spot in the upper part. M Storage conditions PI85 is correctly packed and sealed so they must never be stored in places that omit the followig requeriments: * Humididty between 30% and 95% without condensation. * Temperature from -25 to 55ºC or 75ºC for a length of time no longer that 24 hours (keep in mind that these temperatures are just for storage conditions). * It is advisable not to stack machines or heavy objets on them. * Do not dismantle it for storage. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 6

8 3. MAINTENANCE 3.1. General maintenance - Check up the oil levels every 500 hours work. The oil cap is located at the front part of the deposit. In case of lack of oil fulfil it up until the oil cap indicates 3/4 parts full. - Replacement of hydraulic oil of the container every 2000 hours of work or every three years. Type: CEPSA HIDRAULICO HM 68 Cap to fill up oil Oil level Stop the machine and press emergency stop to make the oil change. Make sure the mandrill has been removed or it s lying on the stand plaque, off the punch route. Once oil has been changed, start up the machine and activate the pedal on and off, increasing the pressure time gradually until the circuit is full. You ll notice that the machine will perform normally. -Lubricate punches regularly as they are used. In case the use is daily and continuous, greas it every day. In case the use is daily but not so continuously, then grease them every week. In case the use is just sporadic, lubricate punches once a month. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 7

9 3.2. Greasing of punches 1. Stop the machine 2. Press down the emergency stop button. 3. Remove frontal protectors using one allen key nº Hold up the punch to be greased and remove the pin pulling up outwards. 5. Extract the punch pulling up upwards. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 8

10 6. Grease the punch as shown in the following picture. 7. Place the punch again as it was at the bigining. 8. Insert the pin. 9. Repeat the process again from point 3 up to 6 for each punch. 10. Put the front protections back to the original position. 11. Cancel emergency stop. 12. Start up the machine 13. Press the pedal some times, continuously so the punch can be slid all along the way. Check up often the punches wearing and the mandrel for its sharpening and distribution. These will depend the use and the material worked with.do not work if wearing is too high or the point has been lost. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 9

11 4. INSTALLMENT AND STARTING UP 4.1. Machine location Try to place the machine correctly so it hasn t got to be moved; in case it has to follow the operations described in the transport section (nº3). The machine must be placed in a flat and levelled surface to avoid vibrations and the movement of it while performing. It s possible to fix it by using bolts since it is provided with a lower base or stand with 4 holes as shown in the following picture Dimensions and working place When locating the machine keep in mind the dimensions of it, theoperative s working place and every possible length of the tube to work with. PI85 have two different working zones, one for the perforation of the mechanism box and the other for the perforation of the bulb shape hole and the handle as shown in the picture. Zone for the perforation of bulb shape and handle Zone for the perforation of the mechanism box 4.3. Admisible outer conditions - Temperature between +5ºC and +40ºC without overpassing an average temperature of +35ºC during 24 hours - Humidity between 30% and 90% without water condensation. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 10

12 4.4. Connection to power supply IMPORTANT This machine must be connected to a power supply with ground connection. PI85 is equiped with a three phased motor 230v / 400v with 1HP connected star like to be plugged to a power supply of 400v.it must be connected to only one power supply and the one indicated. If the line tension is not the proper one, then there mus be made a change of connections in the bobins of the engine and the transformer as indicated in the pictures below: Star Picture for tension 400V (preset) Triangle picture for tension 230V In case of change of voltage from 400V to 230V, switch terminal 6 from 400V to 230V. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 11

13 4.5. Assembling the mandrel back support The machine is provided with the mandrill back stand dismantled and with two screws (allen M8 DIN 912), also there are two nutsm8 DIN 934 to fix the machine. It is important to place and fix the axel well in order to obtain a correct mandrell alignment. Place the back stand in the plate fixing it by fastening the screws DIN 912 and making sure this ones are tight to the DIN 934. It isn t necessary to remove any cover or protection to asssemble it Responsibilities PI85 is according to the European directives and regulations for machine manufacturing. In case of accident due to a negligent use on the operative s side for not fulfilling the usage and safety rules described on this instructions manual, PRADA NARGESA, SL will no take any responsibility. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 12

14 5. OPERATIONS MANUAL 5.1. Mechanism perforation In this section the user will find information on how to perforate the mechanism according to the tube that has been chosen. The machine is equiped to perforate 80% of the kinds of bulb shape locks in the market. It is necessary to follow the following steps: Stop the machine placing the selector to zero Place the tube guide according to the tube to work with. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 13

15 Level up the madrill putting the washers according to the back stand. WASHERS LEVELLING ACCORDING TO THE TUBE TUBE 35 x x x x x x x x x x 80 WASHER TO INSERT Already leveled INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 14

16 Selecting the set of mandrill to work with and add the mandrill some thick parts if required. It is important to place always the thick part with the slot in the lower part to save the tube welding. According to the tube, the fitting-up would be as follows: Assembly for 35mm tube Assembly for 40mm tube Assembly for 40x50mm tube 4 Allen screw ref: M.6 x 16 Assembly for 40x60mm tube 4 Allen screw ref: M.6 x 25 Assembly for 40x70mm tube 4 Allen screw ref: M.6 x 35 INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 15

17 Assembly for 40x80mm tuve 4 Allen screw ref: M.6 x 45 Assembly for 50mm tuve Assembly for 50x60mm tuve 4 Allen screw ref: M.6 x 16 Assembly for 50x70mm tuve 4 Allen screw ref: M.6 x 25 Assembly for 50 x 80mm tuve 4 Allen screw ref: M.6 x 35 INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 16

18 1. Put the set of mandrill in the back stand as shown in the picture. It is important to havethe end where the mandrill is in rest upon the stand plate. Keep in mind to leave always the mandrill in this position whenever it isn t perforated to avoid any crash with the punch. 2. Adapt the top to the desired distance and fix it again. The machine incorporates a standard top that perforates an aproximate length of 184mm in 4 phases. In case it is necessary to perforate different lengths, it is possible to change the top. Consult the manufacturer. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 17

19 3. Insert the mandrill in the tube putting the welding line in the lower part whenever it is possible, until the first top is reached. The tube must be guided by the perforation side as it is indicated in the pictures below. Welding 4. Adjust the upper top leaving an aproximate distance of 3mm with the tube to be perforated, as it is shown in the picture 54A. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 18

20 5. Start up the machine putting the selector in position 1and making sure the emergency stop is cancelled. 6. Press the pedal until it punches the tube and then stop pressing the pedal The punch will return to its initial position automatically. It is necessary to keep in mind that when preesing the pedal all punches will descend at the same time and therefore there must be nothing blocking their route. 7. Pull the tube in the direction pointed in the picture until the top descends one position, then press the tube back against the top to get it adjusted. Repeat steps from nº 6 to 7 descending instead, each time at a position in the top. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 19

21 Extract or place the mandrill resting upon the plate stand. Never leave it within the punch path Simultaneous perforation of the bulb shape cavity and the handle Consists of punching the bulb shape hole and the handle simultaneously at the distance marked by the machine. 1. Stop the machine placing selector in position 0 2. Check up the set of mandrill has been removed or it is leaning on the plate stand, off the rectangular punch path. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 20

22 3. Prepare the lower cut plate at the tube height to be worked with. Tube 35x35 40x40 40x50 40x60 40x70 40x80 Plates for the preparation Thickness 15 mm 10 mm 50x50 50x60 50x57 50x80 Sin grueso 4. In case the height should be changed, remove the lower cut plate by unscrewing both M8 ISO 7380 from the ends and pulling the pin outwards. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 21

23 5. Put the proper thick part in the lower part of the cut plate to reach the desired height according to the tube to be punched. Then put the pins back in and fix them again. 6. Graduate the desired distance to punch the bulb shaped hole and the handle by using the front tops and the milimetre belt. The allowed distance in the machine swings from 18mm up to 37mm approximately. 7. Insert the tube in the the mechanism perforation in the upper cut plate, pressing until you reached the frontal tops that were previously adapted to the desired distance. The tube must be resting upon the upper and lower cut plates. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 22

24 8. Pull the tube towards the upper cut plate until it reaches the top. The tube gets the required play between the mechanism and the bulb shape hole for nearly 80% of this kinds of lock. 9. Hold up the tube in the position indicated in the picture pushing slowly against the tops. 10. Press up the pedal until punching the tube upper wall. Punches will go back to the start position once the pressure on the pedal stops, and the upper tops will avoid the tube from disengaging causing a distortion in the punching operation. It is not necessary to balance the ascent effect of the tube when punches are getting loose because the upper tops absorb this force. It is very important not to punch the whole tube at a time since it might get the operative seriously injured and damage the punches. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 23

25 11. Get the tube out of the upper cut plate at the same time that the upper tops are being set apart by the thumbs. 12. Remove wastes from the inside inclining the tube to one side. - Insert it back again in the upper cut plate and repeat steps from nº 7up to nº 11, punching the whole tube this time instead. When pressing the pedal, the punches will get in by the perforation made before and will descend until they get to punch the lower part of the tube leaving this casing from the top to the bottom. For this process to be correct it is necessary that the tube reaches the top in the same place. - Remove the tube and make sure there isn t any remains inside of it Perforation by parts As it has been seen before, the machine has a standard fixed distance between the bulb shape perforation and the handle; however it is possible to change it by cancelling one of the perforations or just perforating one part of the tube. All these combinations can be achieved by removing one of the punches in some or all the operations required to make these perforations Punch extraction - Stop the machine putting the start selector in position 0. - Unscrew all 4 M6 ISO7380 from the protection sides of the bulb shape punches and the handle and remove it. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 24

26 - Hold up the punch to be cancelled and pull out the pin. - Remove the punch out pulling upwards. - Get the protector and the pin back again. Warning! The machine must always perform with the protection device on. INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 25

27 Perforation with just one punch The process consists of taking out one of the punches and perforate just using this one; with the same pattern as that one for the simultaneous perforation Perforation of bulb shape cavity and handle in just one side Perforate with both punches in the upper side of the tube in the simultaneous perforation and perforate with just one bulb shape punch in the lower side of the tube. It is advisable to perforate all tube by phases in order to improve the time required for the operations Punching with 2mm thick tubes In the stamping PI85 can work both tube of 1.5 mm thickness of 2 mm, depending on the tools purchased with the machine. For all two-walled tubes mm plate placed under the plate lower cutoff of 0.5 mm. A contignación follow the same instructions given in paragraph 5.1. Mechanism perforation Grueso de 0,5mm INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 26

28 6. WARNINGS - Do not handle any part of the machine while it is performing. - Do not use the machine for any other purpose but the ones described in this manual. - Do not work in both perforation zones at the same time. - Wear proper protection gloves for handling all machine components and while working with it. - Wear protection glasses and shoes according to the European protection normative and regulations. - Hold up the tube by the ends, never hold it by the perforation side. - Extract the mandrill set or place it in one of the ends of the stand plate after every use. - Do not work without the protection devices provided with the machine. - Keep a safety distance between the machine and the operative during the time the machine is performing. In case an accident occurs due to a negligent use on the operative side, for not following the usage rules exposed on this manual, NARGESA SL will not take any resposibility Extract mandrill or leave it leaning on the stand plate, after every operation INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 27

29 7. TOOLINGS Tooling for 35X35. Wall thickness 1,5mm REF Pipe Thickness Pieces by tooling Weight 35 x 35 mm 1,5 mm 3 units 5 Kg Tooling for 35X35. Wall thickness 1,5mm REF Pipe Thickness Pieces by tooling Weight 40x40 mm, 40x50 mm, 40x60 mm, 40x70 mm, 40x80mm 1,5 mm 8 units 5,3 Kg Tooling for 40x40mm up to 40x80mm. Wall 2mm REF Pipe Thickness Pieces by tooling Weight 40x40 mm, 40x50 mm, 40x60 mm, 40x70 mm, 40x80mm 2 mm 8 units 5,3 Kg INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 28

30 Tooling for 50x50mm up to 50x80mm. Wall 1,5mm REF Pipe Thickness Pieces by tooling Weight 50x50 mm, 50x60 mm, 50x70 mm, 50x80mm 1,5 mm 7 units 5,5 Kg Tooling for 50x50 hasta 50x80mm. Wall 2mm REF Pipe Thickness Pieces by tooling Weight 50x50 mm, 50x60 mm, 50x70 mm, 50x80mm 2 mm 7 units 5,5 Kg INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS 29

31 Technical annex Press for locks All parts Tooling kit Electric maps Hydraulic map INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 1

32 A1. All parts INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 2

33 INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 3

34 A2. Tooling kit INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 4

35 NUMBER DESCRIPTION 13 RECTANGULAR PUNCH 14 PUNCH Ø 16 S15 SET OF BULB SHAPE PUNCH 32 UPPER CUT PLATE 40 LOWER CUT PLATE 113 ALLEN SCREWS REF.- DIN M6 x TOP 122 CLAMP 123 MANDRILL BAR CLAMPING 125 ROUND HEAD SCREW ISO M8 x 30 S127 MANDRILL OF THICKNESS 10 MANDRILL THICK LOWER THAN 10 MANDRILL OF 50 S130 MANDRILL OF THICKNESS OF 10 MANDRILL OF THICKNESS LOWER THAN 10 MANDRILL OF 40 S133 MANDRILL OF ALLEN SCREW REF. -DIN M6 x ALLEN SCREW REF.- DIN M6 x ALLEN SCREW REF.-DIN M6 x ALLEN SCREW REF.-DIN M6 x INTERCHANGEABLE GUIDE FOR INTERCHANGEABLE GUIDE FOR INTERCHANGEABLE GUIDE FOR THICKNESS OF 10MM LOWER CUT PLATE 142 THICKNESS OF 15 MM LOWER CUT PLATE 143 WASHER OF 30 X 16 X WASHER OF 30 X 16 X WASHER OF 30 X 16 X 5 SC200 PEDAL SET INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 5

36 A3. Electric maps General switch Transformer 50VA INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 6

37 Brown Blue Valve Grey Black Emergency Stop Brown Pedal INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 7

38 Electrovalve Electrovalve Power Contact Terminals Transformer For the operation Pedal Diodes bridge KBJ-15M Thermal protection Motor 4A fuse INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 8

39 A4. Hydraulic map Simple efecto piston Spring return Electrovalve EDI OD A5000 Motor 1CV 230/400V 1450rpm Pump 1.5 l/m 1LO1.5DE10R Pressure limiting 200Bars VMD V 25/04 Air intake filter 2FA 15R 125N Container 15 liters capacity INSTRUCTIONS BOOK PI85 HYDRAULIC PRESS FOR LOCKS A 9

40 WARRANTY REGISTRATION 1. Among on our site 2. Select the menu Warranty Registration 3. Complete the form with your details and press Send 4. The window Message Sent confirms your data has been successfully sent to Prada Nargesa SL. Your machine has been registered and has a warranty of three years in total.